Artificial stone wall facing



June 30, 1953 F, BOUCH 2,643,539

ARTIFICIAL STONE WALL FACING 4 Filed July 15. 1948 2 Sheets-Sheet l qu ma@ June 30, 1953 F. aoUcH ARTIFICIAL STONE WALL FACING 2 Sheets-Sheet 2 Filed July l5, 1948 Patented June 30, 1953 UNITED-,STATES PATENT OFFICE ARTIFICIAL STONE WALL FACING Frank Bouch, Shippenville, Pa.

Application July 15, 1948, Serial No. 38,879

l(ci. *z2-2s) 1 Claim. l

This invention relates broadlyto the art of artificial stone wall facings for the wall surfaces of buildings, and in its more specific aspects it relates to the structure and the process of application and installation of cementitious materials providing such wall facings; and the nature and objects of the invention will be readily recognized and understood by those skilled in the arts to which it relates in the light of the following explanation and detailed description of the accompanying drawings illustrating what I at present believe to be the preferred embodiments and mechanical expressions of my invention from among various other forms, arrangements, combinations and constructions, of which the invention ris capable within the spirit and scope thereof.

It is now common practice in the masonry arts to use artificial stone facings of various types for the exterior walls of new buildings and also in some instances for the interior walls, and also for application to the exterior walls of old buildings. Such artificial stone facings usually consist of several layers of cementitious materials applied to a backing or supporting structure, z

such as an exterior wall of a building. 'Ihe eX- terior surfaces of such artificial stone facings may be formed in various natural stone simulating designs and also may have coloring material imparted thereto so as to more nearly assume the color effect of natural stone. artificial stone facings which have been known in the art it is customary to provide three or more separate coatings or layers of cementitious material. The construction of such a facing involving at least three separate ycoatings or layers of material is, of course, expensive in the cor1- sumpticn of materials and also in the necessity for more labor in the application and installation thereof, and it is therefore an object of my invention to provide an artificial stone wall facing forming the exterior or interior wall surface of a building or the like which consists of only two coatings or layers of material to thereby reduce material as well as labor costs.

The artificial stone wall facings with which am familiar are usually applied directly on a wall of a building or like basic supporting structure and no means is provided for ventilation between such artificial stone facing and the supporting structure. results in the accumulation of moisture between the cementitious facing and the surface of the supporting structure due to lack of air circulation between these parts of the structure, and it is therefore a further object of my invention to In the This type of construction eliminate the accumulation of moisture and to provide insulating characteristics by providing an air chamber or space between the artificial stone wall and its basic supporting structure.

It is also an object of my invention to provide an artificial stone wall facing of the character of this invention in which an air chamber or space is provided between the facing and its basic supporting structure in such manner that air may circulate therein both horizontally and vertically.

In providing an air chamber for the circulation of air in both vertical and horizontal directions between the facing and the basic supporting structure, I have also formed this facing structure in such manner that fresh exterior air may constantly enter the air chamber and dead air therein may iiow completely out of the structure.

And yet another object of my invention resides in the novel construction of the facing reinforcing structure whereby the base coat of the facing is firmly bonded to such reinforcing structure.

Another object of this invention is to provide means whereby the second or finish coat of the facing is bonded to the reinforcing structure as well as to the base coat, whereby a iirm composite structure is produced.

Another object of my invention is to provide a novel, rapid and economical method of treating the base coat whereby the second or finish coat will extend therethrough for iirm bonding with the reinforcing structure.

It is another object of my invention to provide an artificial stone wall facing which may be applied with equal facilityvto brick, tile or other masonry supporting structures as well as to wooden supporting structures.

lt is another object of my invention to provide a two coat or layer artificial stone wall facing in which the finish coat is treated while still in a plastic state to produce a firm finish thereon.

Another object of my invention is to provide a two coat or layer artificial stone wall facing in which the finish coat is treated with sand while still in a plastic state to create an'adhesion of the wet plaster of the finish coat with the sand to produce a firm surface on `the finish coat.

Another object of my invention is to provide a two coat or layer artificial stone wall facing in which sand is applied to, and caused to imbed itself in the finish coat while in a plastic state -to create an adhesion of the wet plaster of the finish coat with the sand to produce a firm surface on the nish coat.

Another object of my invention is to provide a an articial stone wall facing which is adapted to have the exterior surface thereof worked or formed into any desired ornamental configuration.

Another object of my invention is to provide the exterior surface of the facing with beading effects and arrangements simulating a natural stone wall, which beading is caused to adhere permanently to the exterior surface of the facing.

It is anadditional characteristic of my invention to provide structure in the finish coat which lessens the probability of cracks or breaks appearing in the finish coat.

A further feature of my invention resides in the provision of decorative or ornamental means in the finish coat which reduces the possibility of cracks being visible in the finish coat which might result from breaks or cracks in the base coat.

A further object of my invention resides in a particular combination of materials which are mixed together` to provide the coatings forming the composite artificial stone wall facing.

Another object of my invention resides in a new method of constructing and applying an artificial stone wall facing.

With the foregoing general objects, features and results in View, as well as certain others which will be apparent from the following explanation, the invention consists in certain novel features in design, construction, mounting and combinationy of elements, as will be more fully and particularly referred to and specified hereinafter.

Referring to the accompanying drawings:

Fig. l is a perspective view of a building having an exterior artificial stone wall facing constructed in accordance with this invention.

Fig. 2 is a view in elevation, with parts thereof broken away, illustrating the basic and reinforcing structures prior to the application of the articial stone wall facings thereto.

Fig. 3 is a View in vertical section of the basic and reinforcing structures illustrated in Fig. 2 of the drawings.

Fig. 4 is a view in horizontal section of the basic and reinforcing structures illustrated in Fig. 2 of the drawings.

Fig. 5 is a view in perspective, with parts thereof broken away, of a furring strip, illustrating in detail one of the air flow notches formed therein.

Fig. 6 is a view in perspective, with parts thereof broken away, of the base coat applied to the reinforcing structure and being treated while in a plastic state, to provide bonding apertures therethrough.

Fig. '7 is a View in vertical section of the basic and reinforcing structures with the base coat applied on the reinforcing structure.

Fig. 8 is a view in vertical section of the basic and reinforcing structures with the base and finish coats applied thereon, the bonding of the finish coat to the reinforcing structure being illustrated in detail.

Fig. 9 is a View in perspective of the structural elements illustrated in Fig. 8 of the drawings, and with wax or the like paper applied to the wet finish coat and a buffer in operative position thereon for imparting to the finish surface the desired ornamental configuration.

Fig. 10 is a View in perspective of the structural elements illustrated in Fig. 9 of the drawings after completion of the buing operation and with an edger forming the grooves in the finish coat to impart thereto a stone simulating appearance.

Fig. ll is a View in perspective of the structural elements illustrated in Fig. l0 of the drawings with the finish coat being subjected to the sand blasting operation.

Fig. l2 is a view in horizontal section of the two coatings of an artificial stone wall facing in completed condition.

Fig. 13 is a view in vertical section of an artificial stone wall facing applied to a brick or the like basic supporting struct-ure.

Referring to the accompanying drawings, I have used the Vnumeral I to designate the conventional plaster board or the like interior wall of a building which is fixed to the usual vertical studding members 3. Exterior sheeting 5, which may be of any character which is customarily used to provide the exterior wall of a frame building, being attached to the opposite sides of the studding. I have devised an artificial stone wall facing construction and a method of application thereof which may be applied to the walls of buildings which have already been constructed and are of either frame construction or brick, block or other masonry construction. In the particular embodiment of the invention which I am about to describe, the artificial stone wall facing is applied to a previously constructed frame building and the outer original wall 5 thereof may comprise a clapboard wall, shingle wall or any other type of frame or wooden wall.

In preparing the basic supporting structure for the artificial stone wall facing prior to the application of the stone simultating surface thereto, I secure a plurality of vertically disposed spaced fui-ring strips l vwhich are of optional size but are preferably 1" x l". These furring strips are nailed or otherwise secured to the sheeting 5 and are preferably though not necessarily spaced apart approximately 16". The furring strips 'l extend from the top to the bottom of the sheeting 5 which is to be covered by the cementitious stone wall facing and form a part of what I shall term the basic supporting structure of the wall surface. Each furring strip is provided on the inner face thereof adjacent the sheeting 5 with spaced cutout portions or air ow notches 9 therein for a purpose to be hereinafter pointed out. The number of notches 9 which are formed in the furring strips is optional and is dependent upon the size and general characteristics of the wall being covered with the artificial stone wall facing. The furring strips are preferably attached to the sheeting 5 of a frame building by means of aluminum spikes Il which will vary in size in accordance with the dimensions of the furring strips which are being utilized in a particular installation. Thus, the faces of the furring strips which abut the sheeting, when the strips are in sheeting attached operative positions, are cut out to provide a plurality of air ow notches for flow of air past the furring strips in a horizontal direction.

When the required number of furring strips have been attached to the sheeting at spaced intervals therealong, the basic supporting structure for the articial stone wall facing is in readiness for the application and attachment thereto of the reinforcing structure for the facing. Such reinforcing structure or member comprises steel mesh sheeting I3 which may comprise any suitable and desirable type of reticulated or expanded metallic sheeting. I have found 'that standard IAL" steel mesh is one .of several suitable types of mesh. The mesh sheeting I3'is spread over the entire basic reinforcing structure and is attached to the furring strips 1 by nailing thereto in 'any suitable manner. Thus, the basic and reinforcing structures for my artificial stone wall facing may comprise the original wall elements of a frame building and the additional furring strips attached thereto, and the steel or metallic mesh sheeting 1.3, respectively.

After the steelmesh i3 has been ysecurely fixed to the furring strips relatively small sections of metallic screening It, preferably copper, are ate tached in any desirable manner to the steel mesh. These screening sections I4 in the iinished oomposite facing will screen or cover air or ventilating 'apertures 'through the facing and may be placed at any desirable points on the steel mesh. In Fig. 2 of the drawings I have shown, as an example, an `upper and a lower screen section, one on 'the mesh between two furring strips and one on the mesh between the next two furring strips. By following this alternating pattern of an upperscreen section over an area between furring strips and a lower one over the next adjacent area throughout a wall facing it will be recognized that an up and down and horizontal air flow behind the facing will be developed, all as will be clearly explained hereinafter. It is to be understood that these screening sections may be disposed in various `positions on the mesh and still fall within the scope of this invention.

When the 'builder has completed the application of the urring strips and the steel mesh to the original wall structure of the building as explained, the reinforcing structure is in condition for the application thereto of the base coat of the artificial stone wall facing. I have used the numeral I5 to designate in its entirety the base cementitious coating of the stone simulating wall surface.

The base coat i5 may be composed of a ce mentitious mortar plaster material comprising the following substances:

70 lbs, of mortar mix 24 lbs. of cement lbs. of hydrated lime 1% bu. of river sand This mixture forming the base coat I5 is merely one example of a mixture from several which may be used and will provide a satisfactory initial or base coat for my artiiicial stone wall facing, and it is to be understood that the relative quantities of the various ingredients may be varied without departing from the spirit and scope of my invention.

rihe base coat of plaster or cementitious mortar is applied to the steel mesh reinforcing structure I3 with a trowel or steel float to a thickness of approximately 3g, and the applicator thereof imparts sufficient pressure thereto to force a portion of the coat through the steel mesh I3. It is preferable that approximately a quarter of an inch of the cementitious mortar plaster 4protrudes through the steel mesh lf3. Referring partiem ularly to Figs. 6 and l2 of the drawings wherein the protruded section of the rst coat is desig nated by the numeral il and the exterior or nonprotruded section of the base coat is designated by the numeral lil, it will be clearly appreciated that the base coat I5 is firmly bonded or anchored to the reinforcing mesh structure I3 which in turn is securely mounted and attached to the base supporting structure, including the furring strips and the original Wall of the building. In the application of the base coat I5 to the mesh the workman does not cover the screen sections I4 with the plaster, the screen sections therefore function as an indicating means to the workman as well as a cover for the air flow or ventilating apertures. Immediately upon the application of the base coat l5 it is scored 'to a very rough surface in order to assure proper and complete adhesion of the second coat thereto. It is of course understood that this scoring occurs while the first or base coat is still in a plastic condition.

For a purpose to .be hereinafter specically described, the base coat I5 while still in a plastic condition is treated in the following manner to provide a multiplicity of perforations or holes therethrough. Referring particularly to Fig. 6 of the drawings wherein the holes or perforations 2I through the protruded section I? and the nonprotruded section I are illustrated, it will be apparent that such openings or holes in the vbase coat extend all the way through so that the steel mesh at the perforations is open and the interstices therein are not filled with the plaster of the rst coat. I preferably form these perforations or holes ZI completely through the base coat by directing a blast of air from an air gun 23 onto and through the base coat, while the coat of plaster is wet and in a plastic state.

The number of openings 2i may be varied ac cording to the particular installation and the size of each opening may also be varied as well as the positions thereof, and it is to be understood that means other than an air blast may be employed for forming these holes in the base coat.

When the base coat I5 has been applied `to the mesh and treated as described and is in the condition particularly disclosed in Fig. 7 of the drawings, it is allowed to set for a period of nve or six days so that it may dry to a rough hard surface thereby assuring a perfect air tight adhesion for the second or finish coat.

The second or finish coat which is applied directly to the base coat after the latter has set a suiiicient period as above indicated may be composed of the following mixture:

'70 lbs. of mortar mix 24. lbs. of cement 6 lbs. of hydrated lime l1/2 bu. of river sand Coloring pigments in quantities to produce de sired color.

The relative quantities of the components of the nish coat mixture may of course be varied without departing from the spirit and scope of my invention.

The second or nish coat 25 is applied directly on the base coat I5 with a trowel or steel oat to a thickness of 1%, to 1/2 and should the second coat Abe too wet a limited amount of sand may be tossed thereon. In the application of the iinish coat to the base coat suicient pressure is imparted thereon by the workman to cause the iinish coat to firmly adhere to the roughened surface oi the base coat and to cause the finish coat to extend into the apertures 2l in the base coat and through the steel mesh behind said apertures. By this construction the finish coat is provided with a plurality of bonding iingers or anchors El extending through the base coat and through the steel mesh I3 to protrude therethrough as at 229. This construction which is particularly illustrated n Fig. 8 of the drawings insures a facing of two coats which are firmly anchored together and to the supporting structure, it being noted that each coat is firmly anchored to the steel mesh and the finish coat is not merely anchored to the base coat. Thus the component parts of the facing are so bonded together that a permanent unitary structure results.

As in the application of the base coat, the workman does not apply the finish coat over the Ventilating apertures, defined by screen sections I4, which were left in the base coat. Therefore such Ventilating apertures which I shall designate by the numeral I4 extend through both coats of the facing so that air may flow from the exterior to the area between the steel mesh I3 and the sheeting 5. The Ventilating apertures are clearly illustrated in Fig. 1 of the drawings.

After the finish coat has been applied as shown in Fig. 8 of the drawings and is still wet it is bufed so that the exterior surface thereof will assume a natura-1 stone appearance. Referring to Fig. 9 of the drawings wherein the buffng operation on the wet finish coat is illustrated it will be seen that a sheet of wax paper, cellophane or the like 3| is applied to the surface of the wet finish coat and a corrugated buffer 33 is operated over the surface thereof to roughen and produce a natural stone-like surface to the finish coat. The paper 3l is used to prevent the the buffer from sticking to the wet cementitious surface and is, of course, removed upon completion of the bufling operation.

After the completion of the bufng operation and while the finish coat is still in a plastic condition a bevel edged groover 35 (Fig. 10 of the drawings) is used to groove and cut the desired shape and design forming grooves 31 in the finish coat. While I show a roller groover being used it is within my contemplation to employ any other type of groover. The grooves 31 are cut through the rst coat to the outer surface of the second coat as illustrated in Fig. 12 of the drawings. This produces a definite natural stone simulating design or Yornamental effect on the facing and reduces the possibility of breaks or cracks appearing in the finish coat. For instance, if a break or crack occurs in the base coat I5, it would, in most instances follow the grooves 31 in the finish coat so that such breaks would not appear in and mar the appearance of the finish coat.

When the grooves have been formed in the finish coat and while it is still wet and in a plastic state any color sand is blasted on and into the finish coat by means of a sand blasting gun 39, as illustrated in Fig. 11 of the drawings. The sand is blasted on the finish coat preferably under pressures of 75 to 100 lbs. and the sand Will penetrate into the finish coat a distance of approximately lAg" as shown particularly at 4I in Fig. 12 of the drawings.

If desired Carborundum may be combined with the sand which is blasted on and intothe finish coat. The addition of Carborundum to the sand creates the effect of an iron streak on the finish coat which is similar to the streak which appears quite frequently in native stone. The Carborundum when applied with the sand in the blasting operation, is used as a blender and very satisfactory and realistic results are obtained thereby. I wish to point out at this time that it is not essential to add Carborundum to the facing in order to achieve a natural stone effect to the facing, in many instances however 8 the ornamental effect of the facing is enhanced by the addition of the Carborundum.

An adequate composite facing comprising only two coats instead of three or more, results by virtuel of the penetration of the sand into the finish coat, in the sand blasting operation. This penetration of the sand into the finish coat creates an adhesion of the Wet plaster with the sand and produces a firm surface: on the finish coat.

Upon completion of the sand blasting step in the process which I have just described and after the finish coat has been permitted to set and harden for a period of approximately one or two hours the loose sand is scraped out of the grooves or joints 31. In this groove scraping operation it is important for the mason to be certain that the grooves have been formed or cut down to the outer surface of the base coat for the reasons hereinabove described. When the sand has been scraped out of the grooves they are in condition for the beading or jointing process. Mortar mix of two parts, cement 1/4 part, and sand two parts is mixed to` a wet paste and is applied to the joints or grooves 31 by means of a caulking gun for the purpose of beading the stone. The paste is applied to the grooves and a bead 43 which may be approximately 1A is made by the use of a hollow jointing tool which is dipped continuously into water to assure a firmer adhesion of the bead to each side of the groove or joint in the finish coat of the stone simulating facing. After the bead has set for approximately an hour the feather edges are removed with a small pointing trowel.

By the particular construction and mounting of the artificial stone wall facing which I have described it will be appreciated that I have provided a composite facing which is spaced from the basic supporting structure in such manner that an air space is provided therebetween. The furring strips 1 function to mount the reinforcing structure or steel mesh I3 in position spaced from the sheeting 5 so that an air chamber exists between the sheeting and the mesh. Outside air may gain access to this Ventilating chamber through the screened apertures I4', and horizontal as well as vertical air flow is provided for by the air flow notches 9 which are provided in the furring strips 1. Thus air may circulate vertically between adjacent furring strips, air may move horizontally though the notches in the furring strips, and fresh air may flow into the air chamber through the apertures I4', while stale air may exhaust through these apertures I4. Thus Ventilating means is provided throughout the entire space between the original building and the artificial stone wall facing. This is highly advantageous in the elimination of moisture accumulation in this space which would produce deleterious effects on the facing as well as on the interior wall. This air chamber also serves to insulate the building against temperature extremes and also provide desirable acoustical characteristics to the artificial stone wall facing.

It is to be understood that the artificial stone wall facing of this invention may be nished in a great variety of colors and designs, all in simulation of natural stone.

In Fig. 13 of the drawings I have illustrated my artificial stone wall facing as applied to a brick wall of a building and in this form of my invention I have used the same reference numerals to designate parts which are similar to those heretofore described. When the facing is installed on a brick or other wall of masonry construction the furring strips 1 are attached to the brick Wall 45 in the following manner. Holes of a diameter of 1%, to 1/2" in diameter are drilled in the brick, block or other wall to a depth of approximately 11A, at intervals of approximately 18". Lag bolt expanders 41 are inserted in the drilled holes whereupon lag bolts 49 which extend through the furring strips are inserted in the expanders. It will therefore be recognized that the artificial stone wall facing may be applied on a brick, block or other masonry wall with the same facility Iand strength as to a frame wall.

I claim:

A cementitious artificial stone wall facing and a supporting structure therefor including sheeting sections, spaced furring strips secured to said sheeting sections in substantially vertically disposed positions, fo-raminous reinforcing members mounted on said furring strips spaced from said sheeting sections providing air chambers between the sheeting sections and the foraminous reinforcing members, and said furring strips having air flow openings therein permitting 110W of air between adjacent air chambers, said facing including a base coat and a second coat, said base coat bonded to the foraminous reinforcing members and having openings therein for receiving ing members through the openings in the first coat and the second coat having Ventilating apertures therein aligned with the first mentioned Ventilating apertures whereby air may enter and be exhausted from the air chambers.

FRANK BOUCH.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date Re. 20,985 Knight Jan. 24, 1939 372,461 Dryden Nov. l, 1887 616,074 Buckley Dec. 20, 1898 745,547 Wight Dec. 1, 1903 753,491 Hoffman Mar. 1, 1904 769,257 Ewing Sept. 6, 1904 836,727 Woodiwiss Nov. 27, 1906 979,444 DeArmond Dec. 27, 1910 1,280,530 Parker Oct. 1, 1918 1,445,113 Tromanhauser Feb. 13, 1923 1,531,530 Walper Mar. 31, 1925 1,573,897 Alton Feb. 23, 1926 2,045,482 Maier June 23, 1936 2,141,821 Pemberton Dec. 27, 1938 2,189,872 Ulrich Feb. 13, 1940 2,208,191 Kerr July 16, 1940 FOREIGN PATENTS Number Country Date 138,178 Germany Jan. 23, 1903 OTHER REFERENCES Construction Methods, page 43, July 1941. 

